Damper assembly

ABSTRACT

A damper assembly includes a cylinder defining a chamber. The damper assembly includes a body supported by the cylinder and having a first surface and a second surface opposite the first surface. The body defines a passage extending from the first surface to the second surface. One of the first surface or the second surface define a slope at the passage. The damper assembly includes a check disc at the slope, the check disc selectively restricting fluid flow through the passage.

CROSS-REFERENCE TO RELATED APPLICATIONS

The subject patent application claims priority to and all the benefitsof Provisional Patent Application U.S. 63/001,013 filed on Mar. 27,2020, Provisional Patent Application U.S. 63/090,475 filed on Oct. 12,2020, and Provisional Patent Application U.S. 63/090,510 filed on Oct.12, 2020, all three of which are herein incorporated by reference intheir entirety.

BACKGROUND

Dampers are typically used in conjunction with automotive suspensionsystems or other suspension systems to control movement of wheels of avehicle relative to a body of the vehicle. In order to control movement,dampers are generally connected between the sprung (body) and theunsprung (suspension/drivetrain) masses of the vehicle.

The dampers control movement of the wheels by limiting fluid flow past apiston of the damper. The fluid flows past the piston, e.g., viapassages of the piston when the damper is moved toward a compressed orextended position. The passages may have a fixed opening size.Resistance to movement is provided by the passages limiting an amount offluid that flows therethrough. The resistance to movement may increaseexponentially as movement speed is increased.

Discs may be used to control flow of fluid though the passages, e.g., byflexing or translating to increase or decrease a size of an opening atone end of the passage. Changing the opening size may change forceresponse characteristics of the damper assembly. For example, increasingthe opening size may decrease resistance to movement and decreasing theopening size may increase resistance to movement.

It is desired to have further tunability to control the force responseof the damper, and to have reduced manufacturing costs and packagingsize.

SUMMARY

A damper assembly provides variable and tunable resistance and may beconfigured to provide a desired a responsive force that is resistant tomovement of the damper assembly depending on a speed and direction ofthe movement, e.g., toward an extended or compressed position. Thedamper assembly includes a check disc at a slope of a surface of a bodythat defines one or more passages. The check disc at the slope regulatesfluid flow through the one or more passages of the body and controls arate of change of response force provided by the damper assembly, e.g.,controlling an acceleration and/or jerk of the movement of the damperassembly. Other discs may be supported by the body to regulate fluidflow through the one or more passages of the body.

The damper assembly includes the cylinder defining the working chamber.The damper assembly includes the body supported by the cylinder andhaving a first surface and a second surface opposite the first surface.The body defines a passage extending from the first surface to thesecond surface. One of the first surface or the second surface define aslope at the passage. The damper assembly includes a check disc at theslope, the check disc selectively restricting fluid flow through thepassage.

The damper assembly may include an orifice disc between the check discand the body.

The orifice disc may abut the body and the check disc.

The orifice disc may define an orifice between the check disc and thebody, the orifice open in a radial direction.

The slope may be convex.

The check disc may be movable between a first position toward an outeredge of the passage to a second position.

The slope may be concave.

The check disc may be movable between a first position toward an inneredge of the passage to a second position.

The check disc may selectively restrict fluid flow in a first direction,and the damper assembly may include a second check disc selectivelyrestricting fluid flow through the passage in a second directionopposite first direction.

The body may define a second passage extending from the first surface tothe second surface, and the damper assembly may include a blow off discselectively permitting fluid flow out of the second passage.

The check disc may be between the body and the blow off disc.

The blow off disc may define an opening and a center opening.

The damper assembly may include a spacer disc covering the opening ofthe blow off disc.

The damper assembly may include a restriction disc covering a portion ofthe second passage.

The damper assembly may include a spring disc urging the blow off disctoward body.

The damper assembly may include a ring between the spring disc and theblow off disc.

The damper assembly may include a plurality of spring discs urging theblow off disc toward the body, the springs discs progressivelydecreasing in size.

The damper assembly may include a spring urging the check disc towardthe body.

The spring may include a base and a plurality of arms extendingcircumferentially and axially from the base.

The arms may abut the check disc.

In the present disclosure, and as further described herein, the bodydefining one or more passages is provided by the exemplary pistondescribed herein. The piston defines one or more passages. Movement ofthe piston within a working chamber of a pressure tube causes fluid toflow between a compression sub-chamber and a rebound sub-chamber thatare on opposite sides of the piston. Such fluid movement may flex discs,e.g., check discs, blow off discs, spring discs, etc., attached to thepiston. Flex of the discs attached to the piston controls an openingsize of the passages of the piston, regulating fluid flow therethroughand providing variable and tunable resistance to the damper assembly. Asan alternative to the piston, the body may be a base attached to an endof the pressure tube of the damper assembly, the base defining one ormore passages. The passages defined by the base may provide fluid flowbetween the working chamber of the pressure tube and a reservoir chamberoutside the pressure tube. The base may include the surfaces, features,passages, etc., as described for the piston herein. The various discsdescribed herein may be attached to the base, e.g., as described for thediscs attached to the piston, including their orientation, relativepositions, etc. The base and the various discs may collectively providea base valve (or compression valve) assembly that regulates fluid flowbetween the working chamber and the reservoir chamber. Movement of thepiston within the working chamber of the pressure tube may cause fluidto flow between the working chamber and the reservoir chamber via thepassages of the base and may flex the discs attached to the base. Flexof the discs attached to the base controls an opening size of thepassages of the base, regulating fluid flow therethrough and providingvariable and tunable resistance to the damper assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vehicle having a plurality of damperassemblies.

FIG. 2 is a perspective view of one of the damper assemblies.

FIG. 3A is an exploded view of components of a damper assembly.

FIG. 3B is a continuation of the exploded view of FIG. 3A.

FIG. 3C is a continuation of the exploded view of FIG. 3B.

FIG. 4 is a cross-section of a portion of the damper assembly takenalong line 4-4 of FIG. 3B.

FIG. 5A is an exploded view of components of another damper assembly.

FIG. 5B is a continuation of the exploded view of FIG. 5A.

FIG. 5C is a continuation of the exploded view of FIG. 5B.

FIG. 6 is a cross-section of a portion of the damper assembly takenalong line 6-6 of FIG. 5B.

FIG. 7 is the cross section of FIG. 4 and illustrating a first fluidflow path when the damper assembly of FIGS. 3A-4 is moved toward acompressed position.

FIG. 8 is the cross section of FIG. 6 and illustrating a first fluidflow path when the damper assembly of FIGS. 5A-6 is moved toward acompressed position.

FIG. 9 is an illustration of a force response curve of the damperassembly moving toward the compressed position, the illustrationidentifying a first portion of the curve.

FIG. 10 is the cross section of FIG. 4 and illustrating the first fluidflow path when the damper assembly of FIGS. 3A-4 is moved toward thecompressed position with the fluid flow rate and/or pressuredifferential above a first threshold.

FIG. 11 is the cross section of FIG. 6 and illustrating the first fluidflow path when the damper assembly of FIGS. 5A-6 is moved toward thecompressed position with the fluid flow rate and/or pressuredifferential above a first threshold.

FIG. 12 is an illustration of the force response curve of the damperassembly moving toward the compressed position, the illustrationidentifying a second portion of the curve.

FIG. 13 is the cross section of FIG. 4 and illustrating the first fluidflow path and a second fluid flow path when the damper assembly of FIGS.3A-4 is moved toward the compressed position with the fluid flow rateand/or pressure differential above a second threshold.

FIG. 14 is the cross section of FIG. 6 and illustrating the first fluidflow path and a second fluid flow path when the damper assembly of FIGS.5A-6 is moved toward the compressed position with the fluid flow rateand/or pressure differential above a second threshold.

FIG. 15 is an illustration of a force response curve of the damperassembly moving toward the compressed position, the illustrationidentifying a third portion of the curve.

FIG. 16 is the cross section of FIG. 4 and illustrating a third fluidflow path and a fourth fluid flow path when the damper assembly of FIGS.3A-4 is moved toward an extended position with a fluid flow rate and/orpressure differential above a second threshold.

FIG. 17 is the cross section of FIG. 6 and illustrating a third fluidflow path and a fourth fluid flow path when the damper assembly of FIGS.5A-6 is moved toward the extended position with the fluid flow rateand/or pressure differential above a second threshold.

FIG. 18 is an illustration of the force response curve of the damperassembly moving toward the compressed position and a force responsecurve of the damper assembly moving toward the compressed position.

FIG. 19 is an exploded view of components of the damper assembly.

FIG. 20 is a cross section of the components of FIG. 19.

FIG. 21 is a cross section of the components of FIG. 19 illustrating thethird fluid flow path.

FIG. 22 is an exploded view of components of the damper assembly.

FIG. 23 is a cross section of the components of FIG. 22.

FIG. 24 is a cross section of the components of FIG. 22 illustrating thethird fluid flow path.

FIG. 25 is a perspective view of a piston of the damper assembly.

DETAILED DESCRIPTION

With reference to FIGS. 1-6, and wherein like numerals indicate likeparts throughout the several views, a damper assembly 200, 300 for avehicle 30 includes a cylinder 32 defining a working chamber 34. Thedamper assembly 200, 300 includes a piston 202, 302 axially slidablewithin the working chamber 34, the piston 202, 302 having a firstsurface 204, 304 and a second surface 206, 306 opposite the firstsurface 204, 304, the piston 202, 302 defining a passage 208, 308extending from the first surface 204, 304 to the second surface 206,306, one of the first surface 204, 304 or the second surface 206, 306defining a slope 210, 212, 310, 312 at the passage 208, 308. The damperassembly 200, 300 includes a check disc 214, 216, 314, 316 at the slope210, 212, 310, 312 and selectively restricting fluid flow through thepassage 208, 308.

The vehicle 30, illustrated in FIG. 1, may be any type of passenger orcommercial vehicle 30 such as a car, a truck, a sport utility vehicle, acrossover vehicle, a van, a minivan, a taxi, a bus, etc. The vehicle 30includes a body 36 and a frame. The body 36 and frame may be of aunibody construction. In the unibody construction, the body 36, e.g.,rockers, serves as the vehicle frame, and the body 36 (including therockers, pillars, roof rails, etc.) is unitary, i.e., a continuousone-piece unit. As another example, the body 36 and frame may have abody-on-frame construction (also referred to as a cab-on-frameconstruction). In other words, the body 36 and frame are separatecomponents, i.e., are modular, and the body 36 is supported on andaffixed to the frame. Alternatively, the body 36 and frame may have anysuitable construction. The body 36 and/or the frame may be formed of anysuitable material, for example, steel, aluminum, etc.

With reference to FIGS. 1 and 2, the damper assembly 200, 300 controlsmotion of wheels 38 of the vehicle 30 relative to the body 36 of thevehicle 30. The damper assembly 200, 300 provides variable force toresist motion of the wheels 38 relative to the body 36 based on a speedand direction of such motion.

The damper assembly 200, 300 defines an axis A1 extending between endsof the damper assembly 200, 300. The damper assembly 200, 300 may beelongated along the axis A1. The terms “axially,” “radially,” and“circumferentially” used herein are relative to the axis A1 defined bythe damper assembly 200, 300.

The damper assembly 200, 300 is movable from a compressed position to anextended position, and vice versa. A distance between the ends of thedamper assembly 200, 300 is less in the compressed position than in theextended position. Springs or the like may urge the damper assembly 200,300 toward the extended position. Force applied to wheels 38 of thevehicle 30, e.g., from bumps, potholes, etc., may urge to damperassembly 200, 300 toward the compressed position.

The damper assembly 200, 300 provides resistance to motion, i.e.,resistance to moving toward the compressed position or the extendedposition, that is variable as a function of a speed of such motion. Forexample, and with reference to FIGS. 9, 12, 15, and 18, curves C1 and C2illustrate a functional relationship between a velocity (i.e., directionand speed) of movement of the damper assembly 200, 300 and a resistanceto such movement.

With reference to FIGS. 2-6, the damper assembly 200, 300 includes thecylinder 32 that defines the working chamber 34. The cylinder 32 may beelongated along the axis A1 of the damper assembly 200, 300, i.e., thecylinder 32 may be hollow and tubular. The cylinder 32 may be metal, orany suitable material. The working chamber 34 is filled with a fluid,e.g., an incompressible hydraulic fluid.

The damper assembly 200, 300 includes a rod 36 extending away from, andmovable relative to, the cylinder 32. The rod 36 may be elongated alongthe axis A1 of the damper assembly 200, 300. The rod 36 is movedrelative to the cylinder 32 when the damper assembly 200, 300 is movedtoward the compressed position or the extended position.

The rod 36 extends out of the working chamber 34 of the cylinder 32. Forexample, the cylinder 32 may define an opening 38 at an end of thecylinder 32, and the rod 36 may extend from within the working chamber34 to outside the working chamber 34 through the opening 38 at the end.

The piston 202, 302 is slidable within the working chamber 34 along theaxis A1. The piston 202, 302 is supported by the rod 36, i.e., such thatthe piston 202, 302 and rod 36 move relative to the cylinder 32generally in unison. For example, the piston 202, 302 may include acenter opening 40. The rod 36 may be in the center opening 40. Thepiston 202, 302 may be fixed to the rod 36, e.g., via a fastener 41,weld, friction fit, etc. The piston 202, 302 may be metal, plastic, orany suitable material.

The piston 202, 302 divides the working chamber 34 into a compressionsub-chamber 42 on one side of the piston 202, 302 and a reboundsub-chamber 44 on an opposite side of the piston 202, 302. Movement ofthe piston 202, 302 within the working chamber 34 varies volumes of thecompression sub-chamber 42 and the rebound sub-chamber 44. For example,movement of the piston 202, 302 when the damper assembly 200, 300 ismoved toward the compressed position decreases a volume of thecompression sub-chamber 42 and increases a volume of the reboundsub-chamber 44. As another example, movement of the piston 202, 302 whenthe damper assembly 200, 300 is moved toward the extended positionincreases the volume of the compression sub-chamber 42 and decreases thevolume of the rebound sub-chamber 44. Varying the volumes of thecompression sub-chamber 42 and the rebound sub-chamber 44 generates apressure differential therebetween and may cause fluid within theworking chamber 34 to flow from one side of the piston 202, 302 to theopposite side of the piston 202, 302, i.e., from the compressionsub-chamber 42 to the rebound sub-chamber 44, or vice versa. The fluidmay flow from one side of the piston 202, 302 to the opposite side ofthe piston 202, 302 via one or more of the passages 46, 48, 208, 308defined by the piston 202, 302.

Moving the damper assembly 200, 300 toward the extended positiondecreases fluid pressure at the first surface 204, 304 and increasesfluid pressure at the second surface 206, 306. Moving the damperassembly 200, 300 toward the compressed position increases fluidpressure at the first surface 204, 304 and decreases fluid pressure atthe second surface 206, 306. The first surface 204, 304 is between thesecond surface 206, 306 and the compression sub-chamber 42 of theworking chamber 34. The second surface 206, 306 is between the firstsurface 204, 304 and the rebound sub-chamber 44 of the working chamber34. As an example, the first surface 204, 304 may face the compressionsub-chamber 42 of the working chamber 34 and the second surface 206, 306may face the rebound sub-chamber 44 of the working chamber 34.

The piston 202, 302 defines one or more passages 46, 48, 208, 308, e.g.,one or more first passages 208, 308, second passages 46, and thirdpassages 48. The passages 46, 48, 208, 308 extend from the first surface204, 304 of the piston 202, 302 to the second surface 206, 306 of thepiston 202, 302. The passages 46, 48, 208, 308 provide fluidcommunication between the compression sub-chamber 42 and the reboundsub-chamber 44 of the cylinder 32, i.e., such that fluid may flow fromthe compression sub-chamber 42 to the rebound sub-chamber 44 in a firstdirection D1, or vice versa in a second direction D2 opposite the firstdirection D1. The passages 46, 48, 208, 308 may be spacedcircumferentially about the axis A1. A pair of the first passages 208,308 may be spaced opposite each other, i.e., at generally 180 degreesspacing about the axis A1. The second passages 46 and the third passages48 may be between the first passages 208, 308, e.g., circumferentiallyabout the axis A1. The adjectives “first,” “second,” and “third” areused as identifiers and are not intended to indicate significance ororder. For example, the piston 202, 302 may include the first passages208, 308 and the third passages 48 and not the second passages 46. Asanother example, the first direction D1 is shown in the drawings asbeing from the first surface 204, 304 to the second surface 206, 306,however, the first direction D1 may be from the second surface 206, 306to the first surface 204, 304.

The first surface 204, 304 and/or the second surface 206, 306 may eachinclude one or more ribs 50, 52, 54, 56, e.g., an inner rib 50, 52 andone or more outer ribs 54, 56. The ribs 50, 52, 54, 56 extend away fromthe piston 202, 302 to respective distal ends 55, 57. The outer ribs 54,56 may surround second passages 46 and the third passages 48. Forexample, each outer rib 54 of the second surface 206, 306 may surround arespective one of the second passages 46. As another example, each outerrib 56 of the first surface 204, 304 may surround a respective one ofthe third passages 48. The inner ribs 50, 52 may be closer to the centeropening 40 of the piston 202, 302 than the outer ribs 54, 56. The innerrib 50, 52 may be elongated about the axis A1, e.g., surrounding thecenter opening 40.

The second surface 206, 306 and/and or the first surface 204, 304 mayeach define a channel 58, 60. The channels 58, 60 may be radiallybetween the respective inner rib 50, 52 s and outer ribs 54, 56. Thechannels 58, 60 may be elongated about the axis A1, e.g., surroundingthe center opening 40 and the respective inner rib 50, 52.

The second surface 206, 306 and/or the first surface 204, 304 may eachdefine blow off entry areas 62, 64 where fluid may enter the secondpassages 46 or third passages 48. For example, the blow off entry areas62, 64 of the second surface 206, 306 may be at the second surface 206,306 surrounding the third passages 48. As another example, the blow offentry area 62, 64 of the first surface 204, 304 may be at the firstsurface 204, 304 surrounding the second passages 46. The blow off entryareas 62, 64 may be spaced from the distal ends 55, 57 of the respectiveouter ribs 54, 56 along the axis A1. For example, the blow off entryareas 62, 64 may be closer to a radially extending centerline CLcentered on the piston 202, 302 along the axis A1.

The second surface 206, 306 and/or the first surface 204, 304 defineslopes 210, 212, 310, 312 at the first passages 208, 308. The slopes210, 310 of the second surface 206, 306 and the slopes 212, 312 of thefirst surface 204, 304 surround the first passages 208, 308, e.g., atrespective opposite ends of the first passages 208, 308. The slopes 210,212, 310, 312 extend transversely relative to the axis A1, i.e., otherthan perpendicular. For example, the second surface 206, 306 at radiallyinner edges 218, 318 of the first passages 208, 308 may be spaced alongthe axis A1 from the second surface 206, 306 at radially outer edges220, 320 of the first passages 208, 308. As another example, the firstsurface 204, 304 at radially inner edges 218, 318 of the first passages208, 308 may be spaced along the axis A1 from the first surface 204, 304at radially outer edges 220, 320 of the first passages 208, 308.

With reference to the piston 202 illustrated in FIGS. 3B and 4, theslope 210, 212 may be concave, i.e., extending radially away from theaxis A1 and along the axis A1 away from the centerline CL. For example,the second surface 206 at the radially inner edges 218 of the firstpassages 208 may be between the second surface 206 at radially outeredges 220 of the first passages 208 and the centerline CL along the axisA1. As another example, the first surface 204 at the radially inneredges 218 of the first passages 208 may be between the first surface 204at radially outer edges 220 of the first passages 208 and the centerlineCL along the axis A1. An angle between the slope 210, 212 and the axisA1 may be, for example, 91-100 degrees, e.g., as measured on the side ofthe slope 210, 212 proximate the centerline CL.

With reference to the piston 302 illustrated in FIGS. 5B and 6, theslope 310, 312 may be convex, i.e., extending radially away from theaxis A1 and along the axis A1 toward the centerline CL. For example, thesecond surface 306 at the radially outer edges 320 of the first passages308 may be between the second surface 306 at radially inner edges 318 ofthe first passages 308 and the centerline CL along the axis A1. Asanother example, the first surface 304 at the radially outer edges 320of the first passages 308 may be between the first surface 304 atradially inner edges 318 of the first passages 308 and the centerline CLalong the axis A1. An angle between the slope 310, 312 and the axis A1may be, for example, 80-89 degrees, e.g., as measured on the side of theslope 210, 212, 310, 312 proximate the centerline CL.

Returning to FIGS. 3A-6, check discs 214, 216, 314, 316, e.g., a firstcheck disc 214, 314 and a second check disc 216, 316, increase aresistance to movement in response to fluid flow past the respectivecheck disc 214, 216, 314, 316 and/or a difference in fluid pressure onone side of the check disc 214, 216, 314, 316 relative to an oppositeside. The fluid flow and/or difference in fluid pressure may translateor flex the check disc 214, 216, 314, 316 and decease a size of anopening 222, 224, 322, 324 (illustrated in FIGS. 4 and 6) through whichfluid may flow and thereby increase resistance to movement. For example,the check discs 214, 216, 314, 316 may be movable from an unflexedposition illustrated in FIGS. 4, 6-8, 21, and 23 to a flexed positionillustrated in FIGS. 10, 11, 13, 14, 16, 21 and 24.

The check discs 214, 216, 314, 316 may include extensions 226, 326 thatextend radially outward from a base ring 228, 328 of the respectivecheck disc 214, 216, 314, 316. The extensions 226, 326 may be oppositeeach other, e.g., spaced from each other at generally 180 degrees aroundthe axis A1. The check disc 214, 216, 314, 316 may be bow-tie shaped.For example, a width of the extensions 226, 326 may increase along theextensions 226, 326, e.g., such that the extensions 226, 326 get wideras the extensions 226, 326 extend away from the respective base ring228, 328. Each extension 226, 326 may include a pair of contractions230, 330. The contractions 230, 330 may be proximate the respective basering 228, 328. The contractions 230, 330 provide decreased width to theextensions 226, 326 that decreases stiffness of the check disc 214, 216,314, 316 at the contractions 230, 330, e.g., such that the check disc214, 216, 314, 316 flexes at the contractions 230, 330. Althoughillustrated as each having two extensions 226, 326, the check discs 214,216, 314, 316 may each include only one, or more than two, extensions226, 326.

The amount of flex and/or translation of the check disc 214, 216, 314,316 (and the associated decrease in size of the opening 222, 224, 322,324) may be proportional to a rate of fluid flow and/or a pressuredifferential between the compression sub-chamber 42 and the reboundsub-chamber 44 of the cylinder 32. For example, the greater the rate offluid flow and/or difference in fluid pressure, the greater the amountof flex and/or translation of the check disc 214, 216, 314, 316. Athreshold rate of fluid flow and/or difference in fluid pressure may berequired to flex and/or translate the check discs 214, 216, 314, 316.The check discs 214, 216, 314, 316 may not increase resistance tomovement until the threshold rate of fluid flow and/or difference influid pressure is achieved.

The check discs 214, 216, 314, 316 may be supported by the piston 202,302 and/or the rod 36, e.g., via a center opening 232, 332 of each ofthe check discs 214, 216, 314, 316. The piston 202, 302 may be betweenthe rod 36 and the check discs 214, 216, 314, 316. For example, theinner rib 50 of the second surface 206, 306 may be in the center opening232, 332 of the first check disc 214, 314 between the rod 36 and suchcheck disc 214, 314. As another example, the inner rib 52 of the firstsurface 204, 304 may be in the center opening 232, 332 of the secondcheck disc 216, 316 between the rod 36 and such check disc 216, 316. Thecheck discs 214, 216, 314, 316 are supported at the slope 210, 212, 310,312. For example, the extensions 226, 326 of the first check disc 214,314 may cover the slopes 210, 310 of the second surface 206, 306. Asanother example the extensions 226, 326 of the second check disc 216,316 may cover the slopes 212, 312 of the first surface 204, 304.

With reference to FIGS. 4, 7, 10, 13, and 16, the check discs 214, 216may movable from the unflexed positions toward the inner edges 218 ofthe first passages 208 to the flexed position. For example, theextensions 226 of the check discs 214, 216 in the unflexed positions maybe farther from inner edges 218 than in the flexed position.

With reference to FIGS. 6, 8, 11, 14, 17, 21, and 25 the check discs314, 316 may movable from the unflexed positions toward the outer edges320 of the first passages 308 to the flexed position. For example, theextensions 326 of the check discs 314, 316 in the unflexed positions maybe farther from outer edges 320 than in the flexed position.

The first check disc 214, 314 selectively restricts fluid flow throughthe first passages 208, 308 in the first direction D1, i.e., dependingon a direction and an amount of fluid pressure and/or speed of fluidflow applied to the first check disc 214, 314. The first check disc 214,314 selectively permits fluid through the first passages 208, 308 bycontrolling a size of the opening 222, 322 between the first check disc214, 314 and another component of the damper assembly 200, 300, such asthe slope 210, 310 of the piston 202, 302.

When the damper assembly 200, 300 is moved toward the extended positionthe volume of the compression sub-chamber 42 is increased and the volumeof the rebound sub-chamber 44 is decreased, thereby creating a pressuredifferential where fluid pressure is greater in the rebound sub-chamber44 than in the compression sub-chamber 42. Such pressure differentialand/or fluid flow caused by such pressure differential may move thefirst check disc 214, 314 toward the piston 202, 302. Movement of thefirst check disc 214, 314 toward the piston 202, 302 decreases the sizeof the opening 222, 322 therebetween through which fluid may flow.Decreasing the size of the opening 222, 322 increases resistance tomotion provided the damper assembly 200, 300 by limiting fluid flowthrough the first passages 208, 308.

The first check disc 214, 314 may be moved toward the piston 202, 302only when the pressure differential and/or rate of fluid flow is greaterthan a threshold amount. The threshold amount may be determined based ondesired response characteristics of the damper assembly 200, 300, andthe first check disc 214, 314 may be designed, e.g., via geometry suchas thickness, material type, etc., to flex at the threshold amount. Forexample, increasing a thickness of the first check disc 214, 314 and/orselecting a stiffer material for the first check disc 214, 314 mayincrease the threshold amount required to decrease the size of theopening. Decreasing the thickness of the first check disc 214, 314and/or selecting a more flexible material for the first check disc 214,314 may decrease the threshold amount required to decrease the size ofthe opening 222, 322.

When the damper assembly 200, 300 is moved toward the compressedposition the volume of the compression sub-chamber 42 is reduced and thevolume of the rebound sub-chamber 44 is increased, thereby creating apressure differential where fluid pressure is greater in the compressionsub-chamber 42 than in the rebound sub-chamber 44. Such pressuredifferential, and/or fluid flow caused by such pressure differential,may move the first check disc 214, 314 away from the piston 202, 302 andmay not decease the size of the opening 222, 322.

The second check disc 216, 316 selectively restricts fluid flow throughthe first passages 208, 308 in the second direction D2, i.e., dependingon a direction and an amount of fluid pressure and/or speed of fluidflow applied to the second check disc 216, 316. The second check disc216, 316 selectively permits fluid through the second passages 46 bycontrolling a size of the opening 224, 324 between the second check disc216, 316 and another component of the damper assembly 200, 300, such asthe slope 212, 312 of the piston 202, 302.

When the damper assembly 200, 300 is moved toward the compressedposition the second check disc 216, 316 may be moved toward the piston202, 302. Movement of the second check disc 216, 316 toward the piston202, 302 decreases the size of the opening 224, 324 therebetween throughwhich fluid may flow. Decreasing the size of the opening 224, 324increases resistance to motion provided the damper assembly 200, 300 bylimiting fluid flow through the second passages 46. The second checkdisc 216, 316 may be moved toward the piston 202, 302 only when thepressure differential and/or rate of fluid flow is greater than athreshold amount. The threshold amount may be determined based ondesired response characteristics of the damper assembly 200, 300. Thesecond check disc 216, 316 may be designed, e.g., via geometry such asthickness, material type, etc., to flex at the threshold amount, e.g.,as described for the first check disc 214, 314.

The damper assembly 200, 300 may include one or more orifice discs 234,236, 334, 336, e.g., a first orifice disc 234, 334 and a second orificedisc 236, 336. The orifice discs 234, 236, 334, 336 may includeextensions 238, 338 that extend radial outward from a base ring 240, 340of the respective check disc 214, 216, 314, 316. The extensions 238, 338may be opposite each other, e.g., spaced from each other at generally180 degrees around the axis A1. The orifice discs 234, 236, 334, 336 maybe bow-tie shaped. For example, a width of the extensions 238, 338 mayincrease along the extensions 238, 338, e.g., such that the extensions238, 338 get wider as the extensions 238, 338 extend away from the basering 240, 340. Each extension 238, 338 may include a pair ofcontractions 242, 342. The contractions 242, 342 may be proximate thebase ring 240, 340. The contractions 242, 342 provide decreased width tothe extensions 238, 338 that decreases stiffness of the orifice disc234, 236, 334, 336 at the contractions 242, 342, e.g., such that theorifice disc 234, 236, 334, 336 flexes at the contractions 242, 342.

The orifice discs 234, 236, 334, 336 may be supported by the rod 36and/or the piston 202, 302, e.g., via a center opening 244, 344. Theinner rib 50, 52 may be in the center openings 244, 344 of the orificediscs 234, 236, 334, 336. The first orifice disc 234, 334 may be betweenthe first check disc 214, 314 and the piston 202, 302 along the axis A1.The first orifice disc 234, 334 may abut the first check disc 214, 314.The second orifice disc 236, 336 may be between the second check disc216, 316 and the piston 202, 302 along the axis A1. The second orificedisc 236, 336 may abut the second check disc 216, 316. The extensions238, 338 of the orifice discs 234, 236, 334, 336 may be aligned with theextensions 226, 326 of the check discs 214, 216, 314, 316, e.g., tocover the first passages 208, 308 at the slope 210, 310 of the secondsurface 206, 306 and/or the slope 212, 312 of the first surface 204,304.

Each orifice disc 234, 236, 334, 336 defines one or more orifices 246,346. The orifices 246, 346 may be spaced circumferentially around theorifice discs 234, 236, 334, 336. The orifices 246, 346 permit fluidflow axially and/or radially relative to the axis A1 of the damperassembly 200, 300. Each orifice 246, 346 may be open in a radialdirection. For example, orifices 246, 346 may extend radially inwardfrom outer edges 248, 348 of the extensions 238, 338 of the respectiveorifice disc 234, 236, 334, 336, e.g., such that fluid may flow radiallyinto the orifices 246, 346 at the outer edges 248, 348.

The orifice discs 234, 236, 334, 336 may abut the piston 202, 302 andthe check discs 214, 216, 314, 316. For example, the first orifice disc234, 334 may be between, and abut, the first check disc 214, 314 andpiston 202, 302 with the orifice 246, 346 at the outer edge 220, 320 ofthe first passages 208, 308. The second orifice disc 236, 336 may bebetween, and abut, the second check disc 216, 316 and piston 202, 302with the orifice 246, 346 at the outer edge 220, 320 of the firstpassages 208, 308. The orifices 246, 346 enables fluid flow through thefirst passages 208, 308 by maintaining a minimum size to the openings222, 224, 322, 324 between the check discs 214, 216, 314, 316 and piston202, 302 when the check discs 214, 216, 314, 316 are in the flexedpositions. For example, the minimum size of the opening 222, 224, 322,324 may be equal to a radial flow area of the orifice 246, 346.

With reference to FIGS. 3B-4, springs 250, 252 may urge the check discs214, 216 and the orifice discs 234, 236 toward the piston 202. Forexample, a first spring 250 may urge the first check disc 214 toward thesecond surface 206 of the piston 202. As another example, a secondspring 252 may urge the second check disc 216 and the second orificedisc 236 toward the first surface 204 of the piston 202.

Each of the springs 250, 252 may include a base 254 and a plurality ofarms 256 extending circumferentially and axially from the base 254. Thesprings 250, 252 are made from an elastically deformable material, e.g.,spring steel, plastic having suitable elastic properties. The arms 256of the springs 250, 252 may abut the check discs 214, 216. For example,arms 256 of the first spring 250 may abut the first check disc 214. Asanother example, arms 256 of the second spring 252 may abut the secondcheck disc 216.

With reference to FIGS. 5B-6, springs 350, 352 may urge the check discs314, 316 and the orifice discs 334, 336 away from the piston 302. Forexample, a first spring 350 may urge the first check disc 314 and thefirst orifice disc 234, 334 away from the second surface 306 of thepiston 302. As another example, a second spring 352 may urge the secondcheck disc 316 and the second orifice disc 336 away from the firstsurface 304 of the piston 302. The springs 350, 352 may be, for example,washer springs, bended disc springs, coil springs, or any suitable type.The springs 130, 132 may be an elastically deformably material, such asa suitable metal, plastic, etc.

With reference to FIGS. 19 and 20, the orifice discs 334, 336 at thefirst surface 304 and the second surface 306 may abut the piston 302,e.g., without springs there between. For example, the orifice disc 336at the first surface 304 may abut the first surface 304 radially inwardof the first passage 308, e.g., proximate the center opening 40. Theslope 312 of first surface 304 may extend away from the orifice disc336, e.g., toward the centerline CL. The orifice disc 336 may be spacedfrom the first surface 304 at the slope 312 radially outward of thefirst passage 308. As another example, the orifice disc 334 at thesecond surface 306 may abut the second surface 306 radially inward ofthe first passage 308, e.g., proximate the center opening 40. The slope310 of second surface 306 may extend away from the orifice disc 334,e.g., toward the centerline CL. The orifice disc 334 may be spaced fromthe second surface 306 at the slope 310 radially outward of the firstpassage 308. Fluid may fluid into and out of the first passage 308 viaopening 322, 324 between the orifice discs 334, 336 and the respectivefirst surface 304 or second surface 306 outward of the first passage308.

Check discs 314, 316 may be axially outward of the orifice discs 334,336 relative to the centerline CL. The check disc 316 at the firstsurface 304 may abut the orifice disc 336 opposite the first surface304. The check disc 314 at the second surface 306 may abut the orificedisc 334 opposite the second surface 306. The check discs 334, 336control the size of the openings 322, 324, e.g., in response to fluidflow and as described herein.

Spacer discs 355, 357 may be axially outward of the check discs relative314, 316 to the centerline CL. The spacer disc 357 at the first surface304 may abut the check disc 316 opposite 316 the orifice disc 336. Thespacer disc 355 at the second surface 306 may abut the check disc 314opposite the orifice disc 334. The spacer discs 355, 357 separate thecheck discs 314, 316 from restriction discs 66, 68.

The restriction discs 66, 68 may be axially outward of the spacer discs355, 357 relative to the centerline CL. The restriction disc 68 at thefirst surface 304 may abut the spacer disc 357 opposite the check disc316. The restriction disc 66 at the second surface 306 may abut thespacer disc 355 opposite the check disc 314. The restriction discs 66,68 limit flow of fluid past the piston 302, e.g., as further describedbelow.

The springs 351, 353 may be axially outward of the restriction discs 66,68 relative to the centerline CL. Each of the springs 66, 68 may includea main body 67 and a plurality of arms 69 extending circumferentiallyand radially outward from the main body 67 and toward the piston 302along the axis A1. The arms 69 of the springs 351, 353 may abut therestriction discs 66, 68. The arms 69 of the spring 353 at the firstsurface 304 may abut the restriction disc 68 opposite the spacer disc357. The arms 69 of the spring 351 at the second surface 306 may abutthe restriction disc 66 opposite the spacer disc 355. The springs 351,353 urge the restriction discs 66, 68, the spacer discs 355, the checkdiscs 314, 316, and the orifice discs 334, 336 toward the piston 302,e.g., toward the respective first surface 304 or second surface 306.

Blow off discs 74, 76 and spring discs 86 a-86 e, 88 a-88 e may beaxially outward of the springs 351, 353. The blow discs 74, 76 andspring discs 86 a-86 e, 88 a-88 e control fluid flow through the 46 andthe 48, e.g., as further described below.

With reference to FIGS. 22 and 23, the orifice discs 334, 336 may abutthe first surface 304 and the second surface 306 radially inward andradially outward of the first passage 308. The orifice discs 334, 336may seal to the first surface 304 and the second surface 306 about aperimeter of the first passage, e.g., inhibit fluid flow therebetween.The fluid may enter and exit the first passages 308 via the orifices 346of the orifice discs 334, 336. The first surface 304 and the secondsurface 306 may extend generally perpendicular to the axis A1.

Fulcrum discs 359, 361 may be axially outward of the orifice discs 334,336 relative to the centerline CL. The fulcrum disc 361 at the firstsurface 304 may abut the orifice disc 336 opposite 316 the first surface304. The fulcrum disc 359 at the second surface 306 may abut the orificedisc 334 opposite the second surface 306. The fulcrum discs 359, 361separate the orifice discs 334, 336 from the check discs 314, 316 andenable fluid to axially and radially flow into and out of the orifices346 of the orifice discs 334, 336.

Check discs 314, 316 may be axially outward of the fulcrum discs 359,361 relative to the centerline CL. The check disc 316 at the firstsurface 304 may abut the fulcrum disc 361 opposite the orifice discs336. The check disc 314 at the second surface 306 may abut the fulcrumdisc 359 opposite the orifice discs 334. The check discs 334, 336control the size of the openings 322, 324, e.g., in response to fluidflow and as described herein.

Springs 351, 353 may be axially outward of the check discs 334, 336relative to the centerline CL. The arms 69 of the springs 351, 353 mayabut the check discs 334, 336. The arms 69 of the spring 353 at thefirst surface 304 may abut the check discs 336 opposite the fulcrum disc361. The arms 69 of the spring 351 at the second surface 306 may abutcheck discs 334 opposite the fulcrum disc 314. The springs 351, 353 urgethe check discs 334, 336, the fulcrum discs 359, 361, and the orificediscs 334, 336 toward the piston 302, e.g., toward the respective firstsurface 304 or second surface 306.

Blow off discs 74, 76 and spring discs 86 a-86 e, 88 a-88 e may beaxially outward of the springs 351, 353. The blow discs 74, 76 andspring discs 86 a-86 e, 88 a-88 e control fluid flow through the 46 andthe 48, e.g., as further described below.

Returning to FIGS. 3A-6, the damper assembly 200, 300 may include one ormore restriction discs 66, 68, e.g., a first restriction disc 66 and asecond restriction disc 68. The restriction disc(s) 66, 68 limit flow offluid past the piston 202, 302. The restriction discs 66, 68 may besupported by the rod 36 and/or the piston 202, 302. For example, theinner rib 50, 52 may be in center openings 70 of the respectiverestriction disc 66, 68. The first restriction disc 66 may be at thesecond surface 206, 306. The second restriction disc 68 may be at thefirst surface 204, 304. The restriction discs 66, 68 may each includeextensions 72 that extend radially outward.

The first restriction disc 66 may cover a portion of the second passages46. For example, the extensions 72 of the first restriction disc 66 maycover the second passages 46 at the second surface 206, 306. The secondrestriction disc 68 may cover a portion of the third passages 48. Forexample, the extensions 72 of the second restriction disc 68 may coverends of the third passages 48 at the first surface 204, 304.

The damper assembly 200, 300 may include one or more blow off discs 74,76, e.g., a first blow off disc 74 and/or a second blow off disc 76. Theblow off discs 74, 76 may be supported by the rod 36. For example, eachblow off disc 74, 76 may include a center opening 78 and the rod 36 maybe in the center openings 78. The blow off discs 74, 76 may be axiallyoutward of the check discs 214, 216, 314, 316 relative to the piston202, 302. For example, the first check disc 214, 314 may be between thefirst blow off disc 74 and the piston 202, 302. As another example, thesecond check disc 216, 316 may be between the second blow off disc 76and the piston 202, 302.

The blow off discs 74, 76 decrease a resistance to movement in responseto fluid flow past the blow off disc 74, 76 and/or a difference in fluidpressure on one side of the blow off disc 74, 76 relative to an oppositeside. The fluid flow and/or difference in fluid pressure may translateor flex the blow off disc 74, 76 to create, and/or increase a size of,an opening 80, 82 (illustrated in FIGS. 13, 14, 16, 17) through whichfluid may flow. Increasing the size of the opening 80, 82 decreasesresistance to movement by permitting a greater amount of fluid to flowfrom one sub-working chamber 34 to the other sub-working chamber 34. Theamount of flex and/or translation of the blow off disc 74, 76, and theresulting increase in size of the opening 80, 82 may be proportional toa rate of fluid flow and/or the pressure difference between thecompression sub-chamber 42 and the rebound sub-chamber 44 of thecylinder 32. For example, the greater the rate of fluid flow and/ordifference in fluid pressure, the greater the amount of flex and/ortranslation of the blow off disc 74, 76 away the piston 202, 302,providing a greater magnitude of increase of the size the opening 80, 82therebetween. A threshold rate of fluid flow and/or difference in fluidpressure may be required to flex and/or translate the blow off discs 74,76. The blow off discs 74, 76 may not decrease resistance to movementuntil the threshold rate of fluid flow and/or difference in fluidpressure is achieved.

Each blow off disc 74, 76 may define one or more openings 84. Theopenings 84 permit fluid flow from one side of the respective blow offdisc 74, 76 to another side of the respective blow off disc 74, 76. Theopening 84 may decrease a stiffness of the blowoff disc 74, 76. Theopenings 84 may be arranged about the axis A1.

The openings 84 of each blow off disc 74, 76 may circumferentiallyoverlap, i.e., two or more openings 84 may be along a common radiusextending from the axis A1. Such openings 84 may be spaced from eachother along the radius.

The first blow off disc 74 may be spaced from the second surface 206,306 at the third passages 48, e.g., at the blow off entry areas 62.Spacing the first blow off disc 74 from the second surface 206, 306 atthe third passages 48 permits fluid to freely flow into and out of thethird passages 48, e.g., without inhibition of such flow by the firstblow off disc 74.

The first blow off disc 74 selectively permits fluid flow out of thesecond passages 46, i.e., depending on an amount and direction of fluidpressure applied to the first blow off disc 74. For example, the firstblow off disc 74 may selectively permit fluid flow through the secondpassages 46 in the first direction D1. The first blow off disc 74selectively permits fluid flow by controlling the size of the opening 80between the first blow off disc 74 and the piston 202, 302.

When the damper assembly 200, 300 is in the neutral state the first blowoff disc 74 covers the second passages 46 at the second surface 206, 306and restricts or inhibits fluid flow into, and out of, the secondpassages 46. The first blow off disc 74 in the neutral state may abutthe second surface 206, 306 of the piston 202, 302 at the secondpassages 46, e.g., at distal ends 55 of the outer ribs 54 of the secondsurface 206, 306.

When the damper assembly 200, 300 is moved toward the compressedposition the first blow off disc 74 may be moved away from the piston202, 302 by the pressure differential and/or fluid flow resulting fromsuch movement. Moving the first blow off disc 74 away from the piston202, 302 creates the opening 80 between the piston 202, 302 and thefirst blow off disc 74. Fluid may flow out of the second passages 46through the opening 80 to the rebound sub-chamber 44 of the cylinder 32.The first blow off disc 74 may be moved away from the piston 202, 302only when the pressure differential is greater than a threshold amount.The threshold amount may be determined based on desired responsecharacteristics of the damper assembly 200, 300, and the first blow offdisc 74 and other components of the damper assembly 200, 300 may bedesigned, e.g., via geometry such as thickness, material type, etc., toflex at the threshold amount.

When the damper assembly 200, 300 is moved toward the extended positionthe first blow off disc 74 may be urged toward the piston 202, 302, notcreating or enlarging the opening 80 between the piston 202, 302 and thefirst blow off disc 74.

The second blow off disc 76 may be spaced from the first surface 204,304 at the second passages 46, e.g., at the blow off entry areas 64.Spacing the second blow off disc 76 from the first surface 204, 304 atthe second passages 46 at permits fluid to freely flow into and out ofthe second passages 46, e.g., without inhibition of such flow by thesecond blow off disc 76.

The second blow off disc 76 selectively permits fluid flow out of thethird passages 48 of the piston 202, 302, i.e., depending on an amountand direction of fluid pressure applied to the second blow off disc 76.For example, the second blow off disc 76 may selectively permit fluidflow through the third passages 48 in the second direction D2. Thesecond blow off disc 76 selectively permits fluid flow by controllingthe size of the opening 82 between the second blow off disc 76 and thepiston 202, 302.

When the damper assembly 200, 300 is in the neutral state the secondblow off disc 76 covers the third passage 48 at the first surface 204,304 and restricts or inhibits fluid flow into, and out of, the thirdpassage 48. The second blow off disc 76 in the neutral state may abutthe first surface 204, 304 of the piston 202, 302 at the third passage48, e.g. at distal ends 57 of the outer ribs 56 of the first surface204, 304.

When the damper assembly 200, 300 is moved toward the extended positionand pressure is greater in the rebound sub-chamber 44 of the cylinder 32than in the compression sub-chamber 42, the second blow off disc 76 maybe moved away from the piston 202, 302 and create the opening 82 betweenthe piston 202, 302 and the second blow off disc 76. Fluid may flow outof the third passage 48 through the opening 82 to the compressionsub-chamber 42 of cylinder 32. The second blow off disc 76 may be movedaway from the piston 202, 302 only when the pressure differential and/orfluid flow rate is greater than a threshold amount. The threshold amountmay be determined based on desired response characteristics of thedamper assembly 200, 300, and the second blow off disc 76 and othercomponents of the damper assembly 200, 300 may be designed, e.g., viageometry such as thickness, material type, etc., to flex at thethreshold amount.

When the damper assembly 200, 300 is moved toward the compressedposition and fluid pressure is greater in the compression sub-chamber 42of the cylinder 32 than in the rebound sub-chamber 44 the second blowoff disc 76 may be urged toward the piston 202, 302, not creating orenlarging the opening 82 between the piston 202, 302 and the second blowoff disc 76.

With reference to FIG. 25, the first surface 304 and/or the secondsurface 306 may each define one or more notches 99 in fluidcommunication with the passages 46, 48, 308. The notches 99 extendradially outward from the respective passage 46, 48, 308. The notches 99provide bleed flow of fluid into and/or out of the passages 46, 48, 308.Notches 99 at the first surface 304 extending radially outward from thethird passage 48 may provide fluid flow between the first surface 304and the second blow off disc 76 when the second blow off disc 76 coversthe third passage 48. Notches 99 at the second surface 306 extendingradially outward from the second passage 46 provide flow between thesecond surface 306 and the first blow off disc 74 when the first blowoff disc 74 covers the second passage 46. Notches 99 at the firstsurface 304 extending radial outward from the first passage 46 provideflow between the first surface 304 and second check disc 316. Notches 99at the second surface 306 extending radial outward from the firstpassage 46 provide flow between the second surface 306 and first checkdisc 314. The notches 99 extending radially outward from the firstpassage 46 at the first surface 304 and the second surface 306 provideflow into the first passage 46 when the respect check disc 314, 316 isin the flexed position. The notches 99 extending radial outward from thefirst passage 46 at the first surface 304 and the second surface 306 mayreplace the orifice discs 334, 336, e.g., the damper assembly 300 maynot include the orifice discs 334, 336 and the notches 99 may providefluid flow when the respective check disc 314, 316 is flex toward thepiston 302 (e.g., in place of the orifices 346 of the orifice discs 334,336).

With reference to FIGS. 5A-6, the damper assembly 300 may include one ormore spacer discs 354, 356. For example, a first spacer disc 354 may bebetween, and may abut, the first blow off disc 74 and the first checkdisc 214, 314. The first spacer disc 354 may cover the openings 84 ofthe first blow off disc 74. As another example, a second spacer disc 356may be between, and may abut, the second blow off disc 76 and the secondcheck disc 216, 316. The second spacer disc 356 may cover the openings84 of the second blow off disc 76.

Returning to FIG. 3A-6, the damper assembly 200, 300 may include one ormore spring discs 86 a-86 e, 88 a-88 e, e.g., one or more first springdiscs 86 a-86 e and/or one or more second spring discs 88 a-88 e. Thespring discs 86 a-86 e, 88 a-88 e may be supported by the rod 36. Forexample, the rod 36 may extend through center openings 90 of the springdiscs 86 a-86 e, 88 a-88 e. The spring discs 86 a-86 e, 88 a-88 e areelastically deformable. For example, force applied to an outer edge ofthe spring discs 86 a-86 e, 88 a-88 e may cause the spring discs 86 a-86e, 88 a-88 e to flex such that the outer edge is moved axially relativethe respective center opening 90 of the spring disc 86 a-86 e, 88 a-88e. The spring discs 86 a-86 e, 88 a-88 e are made from an elasticallydeformable material, e.g., spring steel, plastic having suitable elasticproperties, etc.

The first spring discs 86 a-86 e urge the first blow off disc 74 towardthe piston 202, 302, i.e., the first spring discs 86 a-86 e increase anamount of force required to flex the first blow off disc 74 away fromthe piston 202, 302. The second spring discs 88 a-88 e urge the secondblow off disc 76 toward the piston 202, 302, i.e., the second springdiscs 88 a-88 e increase an amount of force required to flex the secondblow off disc 76 away from the piston 202, 302.

The spring discs 86 a-86 e, 88 a-88 e may progressively decrease in sizeas a function of the distance from the piston 202, 302 along the axisA1. For example, the first spring disc 86 a closest to the piston 202,302 may have a larger outer diameter than an outer diameter of the firstspring disc 86 b adjacent such first spring disc 86 a, and so on. Thefirst spring disc 86 e farthest from the piston 202, 302 may have adiameter smaller that diameters of the other first spring discs 86 a-86b. As another example, the spring discs 86 a-86 e, 88 a-88 e may beconfigured similar to a leaf spring.

The first spring disc 86 a closest the piston 202, 302 may abut thefirst blow off disc 74 proximate the rod 36. The second spring disc 88 aclosest the piston 202, 302 may abut the second blow off disc 76proximate the rod 36.

The spring discs 86 a, 88 a closest the piston 202, 302 may be spacedfrom the blow off discs 74, 76, at outer edges of the blow off discs 74,76. For example, a first ring 92 may be between the first spring disc 86a and the first blow off disc 74 along the axis A1. As another example,a second ring 94 may be between the second spring disc 88 a and thesecond blow off disc 76. The rings 92, 94 may be circular or anysuitable shape. The rings 92, 94 may be metal, plastic, or any suitablematerial. The rings 92, 94 provide internal preload forces to the springdiscs 86 a-86 e, 88 a-88 e. The rings 92, 94 may be radially outward ofthe openings 84 of the blow off discs 74, 76.

Each damper assembly 200, 300 may include a pair of fulcrum discs 96,98. The fulcrum discs 96, 98 provide fulcrum points for the spring discs86 a-86 e, 88 a-88 e. For example, one of the fulcrum discs 96 may abutthe smallest first spring disc 86 e opposite the adjacent larger firstspring disc 86 d. Such fulcrum disc 96 may have a smaller outer diameterthan the abutting smallest first spring disc 86 e. As another example,the other fulcrum disc 98 may abut the smallest second spring disc 88 eopposite the adjacent larger second spring disc 88 d. Such fulcrum 98disc may have a smaller outer diameter than the smallest second springdisc 88 e.

Each damper assembly 200, 300 may include a pair of preload spacers 100,102. The preload spacers 100, 102 sandwich the piston 202, 302, thediscs 74, 76, 86 a-86 e, 88 a-88 e, and other components of the damperassembly 200, 300 supported by the rod 36. For example, one of thepreload spacers 100 may be axially outboard of one of the fulcrum discs96 and the other preload spacers 102 may be axially outboard of theother fulcrum disc 98. The fastener 41 may fix to the rod 36 axiallyoutboard of the preload spacer proximate the first surface 204, 304. Thefastener 41 may be, for example, a threaded lock nut.

The preload spacers 100, 102 protect the spring discs 86 a-86 e, 88 a-88e. The fastener 41 may confine the preload spacers 100, 102, the blowoff discs 74, 76, the spring discs 86 a-86 e, 88 a-88 e, the piston 202,302, etc., to a stack having a predetermined length. A thickness of thepreload spacers 100, 102 may increase or decrease space available forthe discs 74, 76, 86 a-86 e, 88 a-88 e, the piston 202, 302, etc.

With reference to FIGS. 7, 8, 10, 11, 12, 13 first fluid flow pathsFF1A, FF1B defined by the respective damper assemblies 200, 300 areillustrated. The first fluid flow paths FF1A, FF1B are defined when therespective damper assembly 200, 300 is moved toward the compressedposition. The first fluid flow paths FF1A, FF1B in FIGS. 7 and 8illustrate the respective damper assembly 200, 300 moved toward thecompressed position when a fluid flow rate and/or a pressuredifferential between the compression sub-chamber 42 and the reboundsub-chamber 44 is less than a first threshold.

The first fluid flows path FF1A illustrated in FIG. 7 extends from thecompression sub-chamber 42 around the preload spacer, the second springdiscs 88 a-88 e, and the second blow off disc 76 to the openings 224between the second check disc 216 and the piston 202. From the openings224, the first fluid flow path FF1A extends through first passages 208and out the openings between the first check disc 214 and the piston 202to the rebound working chamber 34.

The first fluid flows path FF1B illustrated in FIG. 8 extends from thecompression sub-chamber 42 around the preload spacer, the second springdiscs 88 a-88 e, and the second blow off disc 76 to the opening 324between the second check disc 316 and the piston 302. From the opening324, the first fluid flow path FF1B extends through first passages 308and out the openings between the first check disc 314 and the piston 302to the rebound working chamber 34.

The first fluid flow paths FF1A, FF1B each define an area, e.g.,perpendicular to the respective first fluid flow path FF1A, FF1B,through which fluid may flow. The defined area may be at narrowestportion of the respective first fluid flow path FF1A, FF1B. The definedarea may include multiple areas. For example, the first fluid flow pathsFF1A, FF1B may split into multiple sub-paths, e.g., with each sub-pathextending through one of the first passages 208, 308. The sub-paths mayeach have a sub-area at a narrowest portion of the respective sub-path,and the defined area of the respective first fluid flow path FF1A, FF1Bmay be a combination of the areas of the sub-paths. Flow through thefirst fluid flow paths FF1A, FF1B may provide bleed flow to equalize thepressure differential between the compression sub-chamber 42 and therebound sub-chamber 44.

When the fluid flow rate and/or pressure differential between thecompression sub-chamber 42 and the rebound sub-chamber 44 is less thanthe first threshold, the areas defined by the first fluid flow pathsFF1A, FF1B provide resistance to movement of the piston 202, 302 bylimiting a rate at which fluid may flow from the compression sub-chamber42 to the rebound sub-chamber 44. Such resistance is illustrated in FIG.9 by a section X of the curve C1.

With reference to FIGS. 10 and 11, the respective damper assembly 200,300 is illustrated as moved toward the compressed position when thefluid flow rate and/or the pressure differential between the reboundsub-chamber 44 and the compression sub-chamber 42 is greater than thefirst threshold. The first threshold may be such that a magnitude of thecurve C1 reaches a predetermined amount of response force within apredetermined amount of time. The predetermined amounts may be based onempirical testing, e.g., to optimize vehicle performance and/or occupantcomfort.

When the fluid flow rate and/or the pressure differential are greaterthan the first threshold, the fluid flow along the first fluid flow pathFF1A, FF1B moves the respective second check disc 216, 316 towards therespective piston 202, 302. Moving the second check disc 216, 316 towardthe piston 202, 302 decreases the size of the opening 224, 324therebetween.

For example, the second orifice disc 236 illustrated in FIG. 10 may bemoved into abutment with the piston 202 at the inner edges 218 the firstpassages 208 and with the second check disc 214, 314 abutting the secondorifice disc 236 opposite the piston 202, thereby minimizing the size ofthe opening 224, e.g., to be generally equal to the radial flow area ofthe orifices 246 of the second orifice disc 236.

As another example, the second orifice disc 336 illustrated in FIG. 11may be moved into abutment with the piston 302 at the outer edges 320 ofthe first passages 308 and with the second check disc 316 abutting thesecond orifice disc 336 opposite the piston 302, thereby minimizing thesize of the opening 324, e.g., to be generally equal to the radial flowarea of the orifices 346 of the second orifice disc 336.

Decreasing and/or minimizing the size of the openings 224, 324 decreasesthe defined area of the respective first fluid flow path FF1A, FF1B, andincreases resistance to movement of the respective damper assembly 200,300 by reducing the rate at which fluid may flow from the compressionsub-chamber 42 to the rebound sub-chamber 44. Such resistance isillustrated in FIG. 12 by a section Y of the curve C1.

With reference to FIGS. 13 and 14, a second fluid flow path FF2 definedby each damper assembly 200, 300 is illustrated. The second fluid flowpath FF2 is defined when the respective damper assembly 200, 300 ismoved toward the compressed position and the fluid flow rate and/or thepressure differential between the compression sub-chamber 42 and therebound sub-chamber 44 is greater than a second threshold. The secondthreshold may be greater than the first threshold such that a slopeand/or magnitude of the curve C1 does not exceed a predetermined amount.The predetermined amount may be based on empirical testing, e.g., tooptimize vehicle performance and/or occupant comfort.

When the fluid flow rate and/or pressure differential is above thesecond threshold the first blow off disc 74 and the first spring discs86 a-86 e are urged away from the respective piston 202, 302 and theopening 80 therebetween is created. The second fluid flow path FF2extends from the compression sub-chamber 42 to the rebound sub-chamber44 via the second passages 46 and the opening 80 between the piston 202,302 and the first blow off disc 74. The second fluid flow path FF2defines an area through which fluid may flow. The defined area of thesecond fluid flow path FF2 may include multiple sub-areas.

The combined defined areas of the first fluid flow path FF1A, FF1B andthe second fluid flow path FF2 reduce resistance to movement of therespective damper assembly 200, 300 (relative to the defined area ofjust the first fluid flow path FF1A, FF1B) by increasing a rate at whichfluid may flow from the compression sub-chamber 42 to the reboundsub-chamber 44. Such resistance is illustrated in FIG. 15 by a section Zof the curve C1.

With reference to FIGS. 16 17, 21 and 24 a third fluid flow path FF3A,FF3B and a fourth fluid flow path FF4 defined by the respective damperassemblies 200, 300 are illustrated. The third and fourth fluid flowpaths FF3A, FF3B FF4, may be defined when the respective damper assembly200, 300 is moved toward the extended position and the fluid flow rateand/or the pressure differential between the compression sub-chamber 42and the rebound sub-chamber 44 is above the second threshold.

The third fluid flow path FF3A illustrated in FIG. 16 extends from therebound sub-chamber 44 to the compression sub-chamber 42 via the firstpassages 208 and the openings 222 between the first check disc 214 andthe piston 202.

The third fluid flow path FF3B illustrated in FIGS. 17, 21, and 24extends from the rebound sub-chamber 44 to the compression sub-chamber42 via the first passages 308 and the openings 322 between the firstcheck disc 314 and the piston 302.

Returning to FIG. 17, the fourth fluid flow path FF4 extends from therebound sub-chamber 44 to the compression sub-chamber 42 via the thirdpassages 48 and the opening 82 between the second blow off disc 76 andthe piston 202, 302.

With reference to FIG. 18, the curve C1 and the curve C2 are shown. Thecurve C1 indicates response force provided by the damper assembly 200,300 moving toward the compressed position at increased speeds. The curveC2 indicates response force provided by the damper assembly 200, 300moving toward the extended position at increased speeds. The variouscomponents of the damper assembly 200, 300 may be configured to controlthe curves C1, C2, i.e., to control an amount of responsive forceprovided by the damper assembly 200, 300 at various speeds.

The curves C1, C2 may be increased or decreased in slope and/or inmagnitude proximate arrows A and A′, e.g., providing tuning for lowspeed movement of the damper assembly 200, 300. For example, increasinga steepness of the slope 210, 310, increasing a stiffness of the checkdisc 214, 314, and/or increasing a size of the orifice 246, 346 of theorifice disc 234, 334 may decrease the slope and/or magnitude of thecurve C1 proximate arrow A. Similarly increasing a steepness of theslope 212, 312, increasing a stiffness of the check disc 216, 316,and/or increasing a size of the orifice 246, 346 of the orifice disc236, 336 may decrease the slope and/or magnitude of the curve C2proximate arrow A′. As another example, decreasing a steepness of theslope 210, 310, decreasing a stiffness of the check disc 214, 314,and/or decreasing a size of the orifice 246, 346 of the orifice disc234, 334 may increase the slope and/or magnitude of the curve C1proximate arrow A. Similarly decreasing a steepness of the slope 212,312, decreasing a stiffness of the check disc 216, 316, and/ordecreasing a size of the orifice 246, 346 of the orifice disc 236, 336may increase the slope and/or magnitude of the curve C2 proximate arrowA′.

The curves C1, C2 may be increased or decreased in slope and/or inmagnitude proximate arrows B and B′. For example, asymmetricallyincreasing a stiffness of the first blow off disc 74 may increase theslope and/or magnitude of the curve C1 proximate arrow B. Similarly,asymmetrically increasing a stiffness of the second blow off disc 76 mayincrease the slope and/or magnitude of the curve C2 proximate arrow B′.As another example, asymmetrically decreasing the stiffness of the firstblow off disc 74 may decrease the slope and/or magnitude of the curve C1proximate arrow B. Similarly, asymmetrically decreasing stiffness of thesecond blow off disc 76 may decrease the slope and/or magnitude of thecurve C2 proximate arrow B′.

The curves C1, C2 may be increased or decreased in slope and/or inmagnitude proximate arrows C and C′, e.g., providing tuning for midspeed movement of the damper assembly 20. For example, decreasing athickness of the rings 92, 94 may decrease the slope and/or magnitude ofthe curve C1 proximate arrow C and arrow C′. As another example,increasing the thickness of the rings 92, 94 may increase the slopeand/or magnitude of the curve C1 proximate arrow C and arrow C′.

The curves C1, C2 may be increased or decreased in slope and/or inmagnitude proximate arrows D and D′. For example, increasing a stiffnessof the first spring discs 86 a-86 d may increase the slope and/ormagnitude of the curve C1 proximate arrow D. Similarly, increasing astiffness of the second spring discs 88 a-88 d may increase the slopeand/or magnitude of the curve C2 proximate arrow D′. As another example,decreasing the stiffness of the first spring discs 86 a-86 d maydecrease the slope and/or magnitude of the curve C1 proximate arrow D.Similarly, decreasing the thickness of the second spring discs 88 a-88 dmay decrease the slope and/or magnitude of the curve C2 proximate arrowD′.

The curves C1, C2 may be increased or decreased in slope and/or inmagnitude proximate arrows E and E′, e.g. to control high speedresponse. For example, increasing a size of the extensions 72 of thefirst restriction disc 66 may increase the slope and/or magnitude of thecurve C1 proximate arrow E. Similarly, increasing a size of theextensions 72 of the second restriction disc 68 may increase the slopeand/or magnitude of the curve C2 proximate arrow E′. As another example,decreasing the size of the extensions 72 of the first restriction disc66 may decrease the slope and/or magnitude of the curve C1 proximatearrow E. Similarly, decreasing the size of the extensions 72 of thesecond restriction disc 68 may decrease the slope and/or magnitude ofthe curve C2 proximate arrow E′.

Although the curves C1, C2 proximate the various arrows A, A′, B, B′, C,C′, D, D′, E, E′ are described individually, the curves C1, C2 may becontrolled based on a cumulative effect of the configuration of thevarious components. For example, configuring the damper assembly 20 tocontrol the curves C1, C2 proximate arrows A, A′, may also change thecurves C1, C2, proximate the other arrows B, B′, C, C′, D, D′, E, E′.

The disclosure has been described in an illustrative manner, and it isto be understood that the terminology which has been used is intended tobe in the nature of words of description rather than of limitation. Manymodifications and variations of the present disclosure are possible inlight of the above teachings, and the disclosure may be practicedotherwise than as specifically described.

What is claimed is:
 1. A damper assembly, comprising: a cylinderdefining a chamber; a body supported by the cylinder and having a firstsurface and a second surface opposite the first surface, the bodydefining a passage in fluid communication with the chamber and extendingfrom the first surface to the second surface, one of the first surfaceor the second surface defining a slope at the passage; and a check discat the slope, the check disc selectively restricting fluid flow throughthe passage.
 2. The damper assembly of claim 1, further comprising anorifice disc between the check disc and the body.
 3. The damper assemblyof claim 2, wherein the orifice disc abuts the body and the check disc.4. The damper assembly of claim 2, wherein the orifice disc defines anorifice between the check disc and the body, the orifice open in aradial direction.
 5. The damper assembly of claim 1, wherein the slopeis convex.
 6. The damper assembly of claim 1, wherein the check disc ismovable between a first position toward an outer edge of the passage toa second position.
 7. The damper assembly of claim 1, wherein the slopeis concave.
 8. The damper assembly of claim 1, wherein the check disc ismovable between a first position toward an inner edge of the passage toa second position.
 9. The damper assembly of claim 1, wherein the checkdisc selectively restricts fluid flow in a first direction, and furthercomprising a second check disc selectively restricting fluid flowthrough the passage in a second direction opposite first direction. 10.The damper assembly of claim 1, wherein the body defines a secondpassage extending from the first surface to the second surface, andfurther comprising a blow off disc selectively permitting fluid flow outof the second passage.
 11. The damper assembly of claim 10, wherein thecheck disc is between the body and the blow off disc.
 12. The damperassembly of claim 10, wherein the blow off disc defines an opening and acenter opening.
 13. The damper assembly of claim 12, further comprisinga spacer disc covering the opening of the blow off disc.
 14. The damperassembly of claim 10, further comprising a restriction disc covering aportion of the second passage.
 15. The damper assembly of claim 10,further comprising a spring disc urging the blow off disc toward thebody.
 16. The damper assembly of claim 15, further comprising a ringbetween the spring disc and the blow off disc.
 17. The damper assemblyof claim 10, further comprising a plurality of spring discs urging theblow off disc toward the body, the springs discs progressivelydecreasing in size.
 18. The damper assembly of claim 1, furthercomprising a spring urging the check disc toward the body.
 19. Thedamper assembly of claim 18, wherein the spring includes a base and aplurality of arms extending circumferentially and axially from the base.20. The damper assembly of claim 1, wherein the body is a piston.